Section 03-06B: Starting System, Diesel Engines
1996 F-250, F-350 and F-Super Duty Workshop Manual
DISASSEMBLY AND ASSEMBLY

Armature Replacement, Starter Motor

  1. Remove positive brush connector from starter solenoid M-terminal.

  1. Remove thru bolt (11091) and separate motor from starter drive gear assembly and drive end housing.

  1. Remove brush end plate screws, brush end plate and bushing (11049) and brush holder (11061) from starter frame and magnet (11075). Remove starter motor armature (11005) from starter frame and magnet.

  1. Install new starter motor armature in starter frame and magnet. Apply a thin coating of Syncolube (PTFE) Low Temperature Grease or equivalent meeting Ford specification ESF-M1C218-A on both ends of armature shaft and pinion.

  1. Install brush holder. Using tool, make sure that brushes fit over commutator. Push black grommet onto frame. Apply grease to bushing bore in brush end plate and bushing and attach to starter frame and magnet.

  1. Position starter frame and magnet tostarter drive (11350) and drive end housing and install thru bolts. Tighten to 5-10 Nm (44-89 lb-in).

  1. Attach positive brush connector to starter solenoid M-terminal. Tighten nut to 9-14 Nm (80-124 lb-in).

  1. Check that starter motor no-load current draw is within specification. Refer to Section 03-06.